technical spunbond production sustainable solutions

From Melt to Nonwovens

Technical spunbond productionSustainable solutions

3Technical spunbond production – Oerlikon Neumag

Your benefits

From Melt to Nonwovens ....................................... 4

Spunbond production with

Oerlikon Neumag technology ................................. 6

Grow with a growing market .................................. 8

Key benefits

Excellent product quality .................................. 10

Low OPEX ......................................................... 12

Leading technology ........................................... 14

Partnering for Performance .................................. 16

Our arguments ...................................................... 18

4 Technical spunbond production – Oerlikon Neumag 5Technical spunbond production – Oerlikon Neumag

Place your business ideas in professional hands! Consulting, engineering, plant construction and high-tech machinery – the whole package from a single source. Many years of experience in textile machine construction and our strong global network form a solid basis and the perfect prerequisites for us as your solutions provider.

Define your nonwoven properties from the very outset

From melt to material – we have your value-added chain

under control. You increase your profit, because an opti-

mized manufacturing process encompassing all production

steps, provides you with the greatest possible influence on

the quality of your end product and your production costs. Add

to this the fact that our brand strength will make financing your

project a profitable investment. Extensive experience and engi-

neering and management competencies help us to even deliver

complex projects and processes on time. You can rely on that!

From Melt to Nonwovens Solutions along the textile value chain

Bitumen Roofing Substrate (for top layer, often flat roofs)

Polymer PET, rPETBasis weight 100 – 300 g/m3

Filament size 2 – 6 dtexStandard product width 1.010 mmMachine standard width (trimmed) 3.030 mm (other widths on request)Line capacity up to 8.000 tons per year

Roofing Underlayment (for use between roofing tiles, wooden roof)

Polymer PP, PE, PETBasis weight 50 - 120 g/m3

Filament size 4 – 7 dtexStandard product width 1.500 mmMachine standard width (trimmed) 3.200 mm (others on request)Line capacity up to 6.000 tons per year

Geotextile (e.g. for surface drainage, erosion control, soil separation)

Polymer PP, PET, rPETBasis weight 80 - 500 g/m3

Filament size 4 - 10 dtexStandard product width 3.200 or 5.900 mmMachine standard width (trimmed) 3.200 or 5.900 mm (others on request)Line capacity up to 10.000 tons per year

Spunbonding DryerCoolingHeatingStretchingNeedle LoomNeedle Loom Accumulator WinderBinderApplicator

Infrared Pre-Heater

Spunbonding Spraying CoolingHeatingStretchingNeedle LoomNeedle Loom Accumulator Winder

Spunbonding Calandering Winder


The Oerlikon Neumag spunbond process is specially designed and developed for the production of technical nonwovens. Polymer, filament and web weight flexibility meeting high industrial quality standards and efficient productivity, are essential for nonwoven producers in this field.

The idea

We offer a one-step nonwoven production process from one

single source – from the raw material to the finished nonwo-

ven roll good.

The Oerlikon Neumag Spunbond process is characterized by

High throughput spinning to enable

cost effective production

High speed spinning capability for high tenacity and

low shrinkage filaments

Optimized melt distribution for eliminating web

performance variation across the width

Robust spinning suitable for a wide variety of

melt spinnable polymers

Decoupled draw slot system to allow optimized

filament characteristics

Mono and bicomponent technology to

meet your requirements

The benefits

We have developed the processes and engineered dedicated

production lines from melt to nonwoven for technical nonwo-

vens:

Low production costs through high capacity production,

less space, machines and operators, low waste rate,

low energy consumption and higher yield

High product performance with low basis weight to

meet the leading market requirements

Spunbond production with Oerlikon Neumag technology

e-save provides you with a competitive edge

With e-save, Oerlikon Manmade Fibers introduced a label for particularly energy-efficient sys-

tems, machines and components back in 2004. Over the past years, e-save has established

itself as the trademark of a comprehensive efficiency program. This underlines the preeminent

role of Oerlikon Manmade Fibers when it comes to commercial success and sustainability.

The Oerlikon Neumag spunbond technology sets standards.

Compared to conventional concepts, this solution convinces in terms of:

Energy: the consumption for compressed air has been reduced by 18%

Economics: reduction of conversion costs by up to 40%

Environment: less than 1% non-recyclable trim waste

Ergonomics: the plant can be operated by only 3 – 5 operators.


More than 5 million tons of technical nonwovens will be consumed in 2015, representing about 60% of the total nonwoven market. The market is growing rapidly with over 6% per year.

State-of-the-art technology with inherent flexibility and future

opportunities are needed. Advanced spunbonds meet the re-

quirements for thinner, lighter and more efficient materials in

technical applications, such as geotextiles and roofing sub-

strates.

Our technology is characterized by a one-step production

process, suitable for nearly all melt-spinnable polymers, with

bicomponent capability, a wide processing window and a

wide range of filaments. Our technology allows you to signifi-

cantly reduce your operational expenses.

We offer the complete nonwoven production process – from

the raw material to the finished nonwoven roll goods – includ-

ing all downstream and auxiliary equipment optimized for the

efficient production of substrates for bitumen roofing mem-

branes and roofing underlayment, geotextiles as well as fur-

ther technical applications.

Grow with a growing market

Souce: SmithersApex (2012/2015)

Total consumption and growth rate in ‘000 tons

Technical Nonwovens Disposal Nonwovens

7 000

6 000

5 000

4 000

3 0002012 2013 2014 2015 2016 2017 2018 2019 2020

Global Nonwoven Consumption

22+7+6+34+14+17+KSource: Edana

Wipes 14.3 % Filtration 7.3 %

Others 17.1 %

Hygiene & Medical 33.6 %

Building & Construction 22.3 %

Automotive 5.4 %

10 Technical spunbond production – Oerlikon Neumag Key benefits 11Technical spunbond production – Oerlikon NeumagKey benefits

Excellent product quality Low OPEX Leading technology

The basis for an excellent end product is an optimum spinning result. It makes no difference whether you want to produce bitumen roofing substrates, roofing underlayments, geotextiles or other techncial nonwovens, our spinning technology is the ideal starting basis.

For optimal spinning, the polymer must be distributed in the

spinning beam under very uniform conditions. With our seg-

mented distribution system, a uniform residence time and

heat transfer is achieved for the polymer across the beam and

spinneret. As a result of the excellent polymer distribution, our

spunbond technology achieves homogeneous web charac-

teristics. To this end, consistent tenacity and elongation values

in both cross and machine direction, are achievable.

The results are:

Bitumen roofing substrate nonwovens from 100% PET

spunbond with our technology are comparable to glass

fiber reinforced products.

High grade roofing underlayment nonwovens, a high

standard with future opportunities.

Geotextile nonwovens with excellent properties and

best cost/performance ratio

One basis, many possibilities

Improved strength at lower basis weightl (Benchmark example)

Geotextile

10

5

0

tens

ile s

tren

gth

[kN

/m]

Oerlikon Neumag product 120 g/m2 EU benchmark product 130 g/m2

Bitumen roofing substrate

800

400

0

MD MD MD MDCD CD CD CD

tens

ile s

tren

gth

in N

/50m

m

Oerlikon Neumag product 170 g/m2 EU benchmark product 180 g/m2

13Technical spunbond production – Oerlikon Neumag12 Technical spunbond production – Oerlikon Neumag Key benefits

Low consumption values for energy, gas, air and water, low personnel requirement as well as a low waste rate with raw material consumption, ensure that the investment of your plant is amortized within 2-4 years.1

High throughputs

Our spunbond technology enables significantly higher

throughputs than achievable with other standard systems

available on the market: up to 300 kg/(h*m) for virgin polyester

and up to 240 kg/(h*m) for polypropylene.

Low energy consumption

As a result of the optimization of the draw slot and a process

optimization, the energy consumption for compressed air has

been reduced, compared to our previous solutions, by 18%.

Low waste rate

Due to the high system up-time with planned maintenance

intervals and the possibility of recycling the majority of the

waste, the non-recyclable trim waste is less than 1%.

Economical plant

Our one-step spunbond process from chips to roll goods

eliminates the need of semi-product stores and saves space

in particular vs. two-step processes like carding (fiber and

nonwoven production). Our compact spinning units need a

maximum height of 12 meters. An additional building level for

the processing is not necessary.

Due to easy-to-operate components and our single process

control system, the plant can be operated by only 3-5 oper-

ators.


High production capacities at low costs

1 At full production and 25% sales margin of the nonwoven roll good on average.

100

50

%

100

50

%

Bitumen roofing substrate production

Geotextile production

Oerlikon Neumag

process

Competitive

spunbond process

Example conversion costs (excl. raw material)

15Technical spunbond production – Oerlikon Neumag14 Technical spunbond production – Oerlikon Neumag Key benefits


With more than 100 systems for PET, PP and bicomponent staple fibers installed worldwide – with production capacities in excess of 4.3 million tons/ year – we are able to draw on comprehensive and proven know-how in the processing of polyester and polypropylene. This expertise is deployed for your benefit in the production of technical nonwovens.

All key components of the Oerlikon Neumag spunbond tech-

nology are manufactured in our factory in Neumünster. We

also work with renowned partners.

Outstanding flexibility in polymer use

Our spunbond technology is designed for a wide variety of

melt spinning polymers such as PET, R-PET, PP, PE, PA, PLA

and PPS.

Additionally, our lines can be optionally equipped with bicom-

ponent technology which has been installed in a number of

commercial lines. Our unique bicomponent system allows:

Core/sheath with a sheath content as low as 5%

Decreased costs per unit with cost-efficient polymer,

e.g. recycled polymer in the core

A wide range of polymer combinations,

polymer ratios and viscosities

Adding value by utilizing different core and sheath

properties, e.g. strength, softness and elongation

Draw slot technology

In the draw slot, the filaments are accelerated by induced

compressed air, thus controlling the filament draw ratio. The

drawing is independent of the spinning and quenching for ob-

taining the desired filament characteristics.

Our draw slot is designed to enable an improved air veloci-

ty distribution over the draw slot width. This design offers a

more homogeneous distribution and thus a more homoge-

neous web-formation. The achieved, significantly lower ba-

sis weight spread results in the reduction of the mean basis

weight by maintaining required technical characteristics like

tensile, puncture and tear strength, thus leading to savings in

polymer costs.

Improved forming zone

Better formation for less edge trim and therefore savings in

raw material costs.

In the forming zone, which directly adjoins the draw slot, the

filament speed is reduced in order to open and oscillate the

filaments for a homogeneous distribution and fiber orientation.

Our forming zone design allows a controlled air and filament

guidance for achieving clear and homogeneous web edges.

Therefore the edge trim can be significantly reduced or even

eliminated – depending on the product requirements.

The suction box offers a more robust formation and a wider

process window which is essential for a broad and flexible

product portfolio. Our design leads to controllable settings

for individual products, improved formation freezing and im-

proved web transfer.

This results in an extended process flexibility which enables

the production of nonwovens with varying characteristics in

terms of:

Polymers used,

Filament fineness and cross sections,

Fiber orientation and

Basis weights.

Innovative, powerful and flexible – nonwovenproduction with Oerlikon Neumag technology


Progress is steaming ahead within the textile machine and systems construction sector, with production processes continually improving. However, production processes are also becoming increasingly complex and require reliable steering and monitoring to prevent expensive machine downtimes.

Those dispensing with optimally-tuned service are taking a

huge risk: investments can quickly become absolutely worth-

less if the technology or the service fails to be future-proof or

performance-compliant.

Collaborating with you, Oerlikon Manmade Fibers’ mission

statement is to ensure that your production processes run

smoothly. For this reason, our motto and ambition is: Partnering

for Performance. This stands for a service initiative benefiting

all customers who expect more than just service alone. The

Partnering for Performance offers ensure that your systems re-

main state-of-the-art: profitable and ready for operation, hence

ensuring you make a sound decision – for future-proof invest-

ment, for technological leadership and for production reliability

in your day-to-day operations.

Think globally, act locally

Under the Partnering for Performance umbrella, our Oerlikon

Manmade Fibers Service offers a plethora of the most diverse

products and services to ensure that you reliably achieve your

goals: faster return-on-investment (ROI), shorter downtimes

and optimized production processes. We will swiftly and ef-

ficiently implement your requirements – at any time and any-

where, a pledge that is backed up by highly-qualified employ-

ees at our headquarters in Germany along with our network of

over 20 worldwide service stations.

Partnering for Performance Maintain your success!

Find out more on

Oerlikon Neumag Customer Services

Or contact us:

[email protected]

Our arguments

With our Oerlikon Barmag and Oerlikon

Neumag competence brands, we are

the world market leader for manmade

fiber filament spinning systems, textur-

ing machines, BCF systems, staple fiber

systems and artificial turf systems. As a

service provider for engineering and af-

tersales services, we offer total solutions

for the entire textile value added chain.

We attach great importance to energy

efficiency and sustainable technologies

in all our developments.

To what extent do you profit from this?

Our market position guarantees you the

benefits and quality of leading technolo-

gies, our sustainable products save you

money and our comprehensive services

save you time and hence increase your

profit.

More on Oerlikon Neumag

Spunbond solutions

Or contact us:

[email protected]

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Oerlikon NeumagZweigniederlassung der Oerlikon Textile GmbH & Co KGChristianstrasse 168 – 17024536 NeumuensterGermanyT +49 4321 305 265F +49 4321 305 [email protected]/manmade-fibers

technical spunbond production sustainable solutions

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